Axial-Flow Separator With Internal Thread for Low Pressure Drop
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Solution Overview
Problem
Existing cyclone separators, both counter-current and direct-current types, face inefficiencies in particle-fluid separation, particularly when particle and fluid densities are similar, leading to reduced separation efficiency and increased pressure drop, and are not easily retrofittable to existing systems.
Innovation Solution
A direct current cyclone separator with a hollow cylindrical pipe section featuring an internal thread that generates swirl, maintaining a constant flow direction and enhancing centrifugal separation by imparting a tangential velocity component to the dispersion, utilizing guide vanes and baffles to maintain rotational motion and enhance separation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If a direct current cyclone separator is used, then the pressure drop is reduced and retrofitting is enabled, but the separation efficiency between particles and fluid is reduced
Solution Approach 1:
The patent applies local quality by creating a velocity maximum at the pipe wall through the internal thread structure. This localized velocity enhancement at the wall region increases centrifugal forces where particles need to be separated, improving separation efficiency specifically in the critical wall region without requiring overall flow direction changes that would increase pressure drop.
Solution Approach 2:
The internal thread structure with increasing helix angle creates a curved flow path that generates rotational motion. The helical curvature of the threads imparts tangential velocity to the flow, creating the necessary centrifugal forces for particle separation while maintaining axial flow direction, thus avoiding the pressure drop associated with perpendicular deflection.
2Speed
If the maximum velocity is located midway between pipe wall and center, then particles are moved radially outwards, but the force acting on particles is reduced the further they move away from the area of maximum speed
Solution Approach 1:
The internal thread structure with increasing helix angle creates a localized velocity maximum at the pipe wall rather than in the center. This local quality change ensures that the strongest centrifugal forces act where particles are located (near the wall), maximizing the separation force where it is most needed rather than distributing it uniformly or peaking at the center.
Solution Approach 2:
The helix angle of the internal thread increases along the flow direction, dynamically adjusting the tangential velocity component. This dynamic structure creates progressively stronger rotational effects along the flow path, ensuring that particles experience increasing centrifugal forces as they travel through the separator, enhancing separation efficiency.
3Productivity
If the dispersion is directed into a vessel with rounded side wall (counter-current cyclone), then particles are forced radially outwards and collected at the bottom, but the space requirement is increased and retrofitting is not possible
Solution Approach 1:
The patent inverts the conventional counter-current cyclone approach by using direct current (axial) flow instead of perpendicular flow. The internal thread structure generates the necessary rotational motion and centrifugal forces within the axial flow path, eliminating the need for large rounded vessels and perpendicular flow deflection, thus enabling retrofitting into existing systems with reduced space requirements.
Solution Approach 2:
The invention extracts the essential separation function (generating centrifugal forces for particle separation) from the complex counter-current cyclone structure. By using a simple internal thread structure in an axial flow system, it separates the core separation mechanism from the bulky vessel geometry, enabling compact designs that can be retrofitted into existing systems.
4Productivity
If counter-current cyclone separator is used, then particles are separated from fluid, but further deflections of the dispersion are necessary and manufacturing costs are increased
Solution Approach 1:
The patent merges the flow direction maintenance function with the particle separation function into a single axial flow path. The internal thread structure simultaneously generates rotational motion for separation while maintaining axial flow direction, eliminating the need for separate deflection components and reducing overall system complexity compared to counter-current designs.
Solution Approach 2:
The internal thread structure serves multiple functions: it generates rotational motion, creates centrifugal forces for separation, and maintains axial flow direction. This multi-functionality reduces the need for additional components and simplifies the overall system design, making it more adaptable to existing infrastructure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Achieves up to 80% efficiency in fluid discharge and 95% particle separation with reduced construction costs and pressure drop, allowing retrofitting into existing systems and maintaining high separation efficiency despite similar particle and fluid densities.
Implementation Method 1
an internal thread (36) is provided on an inner wall (32) of the pipe section (12), in order to generate swirl
Implementation Method 2
the particles are moved radially outwards, while the fluid is moved essentially in the center of the direct current cyclone separator
Data Source
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AI summary
The invention relates to an axial-flow centrifugal separator (4) for separating particles (10) from a dispersion (6), in particular a suspension, which contains the particles (10) and a fluid (8), the separator (4) comprising a hollow cylindrical pipe section (12) for conducting the dispersion (6) in a conducting direction (34). An inner wall (32) of the pipe section (12) has an internal thread (36), the lead angle (40) of which increases in the conducting direction (34).